Flushness shims

ABSTRACT

A media player according to the invention is provided. The media player may include a scroll wheel and a housing including a retention ledge. The retention ledge may maintain the position of the scroll wheel with respect to the housing. A flexible printed circuit may also be included in the media player. The flexible printed circuit may include a first face and a second face. The first face may contact the scroll wheel. The second face may include tactile dome switches. Compressible shims may also form a portion of the media player and may be adjacent the second face. The compressible shims may control the distance between the scroll wheel and the retention ledge.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of copending, commonly-assigned U.S.patent application Ser. No. 11/519,284, filed Sep. 11, 2006, which isfully incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

This invention can relate to apparatus and methods for improving theconstruction of portable media players. More particularly, thisinvention can relate to maintaining the effectiveness of construction ofportable media players across a range of operational conditions.

BACKGROUND OF THE INVENTION

On many portable electronics with tactile button interfaces, there is aneed to have the surface of the button as close to flush as possiblewith the surface of the housing in which it sits. This is exemplified inthe current line of iPod™ products made by Apple Computer Inc., ofCupertino, Calif., which have scroll wheel interfaces. Scroll wheelinterfaces permit a user to run a finger around the wheel to navigatethrough menus. Because dome switches beneath the surface of the wheelcan be actuated when pushed intentionally by the user, there is anassembly tolerance gap between the dome switch and its actuator.

As a result of this gap, there can be a small amount of “play” in thefit of the wheel to the housing. This “play” can have a negative impacton the feel of the device. It would therefore be desirable to reduce thegap by having the wheel justified toward the face of the product. Itwould also be desirable to implement this reduction via a separatemechanism from the dome switches beneath the scroll wheel.

In addition, other product designs may be implemented with a siliconesheet directly behind the wheel and the housing. The silicone sheet canhelp to keep the two planes flush. However a need exists for a moreefficient system for maintaining the two planes substantially,consistently flush.

SUMMARY OF THE INVENTION

One embodiment of the invention can be directed to reducing thetolerance gap to a minimum across a predetermined operational range ofthe device. The tolerance gap exists because the dome switches cannot bepre-compressed when the device is operational. Thus, the design takesinto account the largest nub and the lowest dome to provide a tolerancegap which the device can provide such that the dome switches are notpre-compressed in all manufacturing situations. However, the tolerancegap may result in a certain amount of “play” across the range ofoperation of the invention. Compressible shims or another suitabledevice according to the invention preferably provide a force thatmaintains the tolerance gap at a minimum, or at least at a reducedvalue, across the predetermined operational range of the device.

A media player according to the invention is provided. The media playermay include a scroll wheel and a housing, which has a retention ledge.The retention ledge can accurately position the scroll wheel withrespect to the housing. The media player may also include compressibleshims that control the distance between the scroll wheel and theretention ledge.

In one embodiment of the invention, the scroll wheel may be implementedto actuate, directly or indirectly, dome switches on a flexible printedcircuit. The flexible printed circuit may be under, in contact with, orproximal to, the scroll wheel. In this embodiment, the shims shouldpreferably be implemented so as not to affect the operation of the domeswitches.

In another embodiment of the invention, at least one or more springs maybe implemented instead, or in combination with, the foam shims.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example, and not by wayof limitation, in the figures of the accompanying drawings and in whichlike reference numerals refer to similar elements and in which:

FIG. 1 is a perspective view of a media player, in accordance with oneembodiment of the present invention;

FIG. 2 is a top plan view of scroll wheel 202 and center button 204 of amedia player according to the invention;

FIG. 3 shows a cross-section of the scroll wheel 202, button 204, andhousing 206 from Line A-A in FIG. 2 according to the invention;

FIG. 4 shows a cross-section of the scroll wheel 202, button 204, andhousing 206 from Line B-B in FIG. 2 according to the invention;

FIG. 5 shows an exploded portion of FIG. 4 taken from curve C in FIG. 4;

FIG. 6 shows an exploded perspective view from below of the flushnessshims and related apparatus according to one embodiment of theinvention;

FIG. 7 shows an exploded perspective view from above of the flushnessshims and related apparatus according to one embodiment of theinvention;

FIG. 8 shows one embodiment of a method according to the invention;

FIG. 9 an exploded perspective view from below of a single spring andrelated apparatus according to one embodiment of the invention; and

FIG. 10 shows an exploded perspective view from above of a plurality ofsprings and related apparatus according to another embodiment of theinvention.

DETAILED DESCRIPTION OF THE DISCLOSURE

The invention can relate to obtaining a substantially coplanarrelationship between two surfaces—i.e., a relationship wherein the twosurfaces are parallel, within a few degrees, to one another andsubstantially are part of a single plane—in a media player. In onespecific embodiment, the invention may relate to obtaining asubstantially coplanar relationship between a scroll wheel in a mediaplayer and the housing of the media player. A substantially coplanarrelationship may be advantageous to prevent dust from entering the mediaplayer and to protect the media player's internal components in otherways, which will be described below.

In one embodiment of the invention, flushness shims, which can be madeof a soft foam-like material manufactured by Nitto Denko, of Japan(www.nitto.co.jp), may be placed in such a way as to exert pressure onthe scroll wheel. In one embodiment, the foam is soft enough that thefoam does not “deaden” the feel of a dome switch when the foam ispartially compressed. In one embodiment, the shims can be symmetricallylocated (e.g., at 45° locations) around the scroll wheel while the domeswitches may, in one embodiment, be placed at the 90° locations. In thisway, the foam can only partially compress when the dome switch button isactuated. Also the compression of the foam may act to prevent creep overtime.

In one embodiment of the invention, the foam can apply pressure from theunder side of the wheel to push the face of the wheel flush with thehousing. The foam can be in a pre-compressed state to apply the pressureconsistently across the operational range of the media player. The foammanufactured by Nitto, for example, is particularly advantageous forthis because it can be compressed to 10% of its non-compressedthickness. The Nitto foam is made in many thicknesses, but an about 1.0millimeter (mm) thickness can be used for the scroll wheel applicationthat can be nominally—i.e., with no user compression of thewheel—compressed to about 0.65 mm. The about 1.0 mm foam couldtheoretically be compressed down to as little as about about 0.1 mm(10%). When the dome switch is activated, the foam may get compresseddown to about 0.4 mm. The minimum 0.4 mm thickness during activation ofthe dome switch allows the foam to be in substantially constantcompression while preventing wear or creep over time.

The Nitto material was originally designed as an LCM (Liquid CrystalMatrix display) gasket for portable electronics. The Nitto foam is knownfor its shock-absorbing qualities and ability to keep dust out of adisplay assembly. It is not essential that the material used for theflushness shims according to the invention be the Nitto material.Rather, any suitable foam having suitable mechanical properties may beused according to the invention.

The following physical characteristics are beneficial in certain shimsaccording to the invention. First, the shims should possess an abilityto take a pre-compression without creep. In one embodiment,pre-compression can be sufficient to overcome assembly tolerances withrespect to the distance between the scroll wheel and the housingsurface. In one iPod™ device, for example, the foam should be able to bepre-compressed to about 0.2 mm to overcome possible factory conditionwithin the part specifications.

The shims may also possess the ability to maintain a substantiallyconstant push-back force. The shims can also include a relatively lowcompressive force so as not to “deaden” the feel of nearby buttons. Inother embodiments, a similar effect as the effect created by the foamshims may be created with a large, soft spring that may be concentricwith the wheel or center button. This may be a more complex mechanism,but it is conceivable that it could have the same function.Alternatively, in another embodiment of the invention, the effectcreated by the foam shims may be obtained by using a plurality ofsprings which may be used to create the same force and action of thefoam.

FIG. 1 is a perspective diagram of media player 100, in accordance withone embodiment of the present invention. The term “media player”generally refers to computing devices that are dedicated to processingmedia such as audio, video or other images, as for example, musicplayers, game players, video players, video recorders, cameras, and thelike. In some cases, the media players contain single functionality(e.g., a media player dedicated to playing music) and in other cases themedia players contain multiple functionality (e.g., a media player thatplays music, displays video, stores pictures and the like). In eithercase, these devices are generally portable so as to allow a user tolisten to music, play games or video, record video or take pictureswherever the user travels.

In one embodiment, the media player is a hand-held device sized forplacement into a pocket of the user. By being pocket sized, the userdoes not have to directly carry the device and therefore the device canbe taken almost anywhere the user travels (e.g., the user is not limitedby carrying a large, bulky and often heavy device, as in a laptop ornotebook computer). For example, in the case of a music player, a usercan use the device while working out at the gym. In case of a camera, auser can use the device while mountain climbing. In the case of a gameplayer, the user can use the device while traveling in a car.Furthermore, the device can be operated by the users' hands; noreference surface such as a desktop is needed. In the illustratedembodiment, media player 100 is a pocket-sized hand-held MP3 musicplayer that allows a user to store a large collection of music. Althoughused primarily for storing and playing music, the MP3 music player shownherein can also include additional functionality such as storing acalendar and phone lists, storing and playing games, storing photos andthe like. In fact, in some cases, it can act as a highly transportablestorage device.

Electronic device 10 can also be any miniature consumer electronicdevice. Miniature electronic devices may have a form factor that issmaller than that of hand-held devices. Illustrative miniatureelectronic devices can include, but are not limited to, watches, rings,necklaces, belts, accessories for belts, headsets, accessories forshoes, virtual reality devices, other wearable electronics, accessoriesfor sporting equipment, accessories for fitness equipment, orcombinations thereof.

By way of example, the MP3 music player can correspond to the iPod™ MP3player manufactured by Apple Computer of Cupertino, Calif. Onepocket-sized IPod™ has a width of about 2.4 inches, a height of about 4inches and depths ranging from about 0.72 to about 0.84 inches, althoughany relatively small size is possible.

As shown in FIG. 1, the media player 100 FIG. 1 also shows housing 102,display screen 104, scroll wheel 110, center button 112, holdswitch 114,and earphone jack 116 of media player. Housing 102 can host centerbutton 112, and can in fact be configured to retain scroll wheel 110 inits position in the media player. Navigation can be implemented in theform of transmission of user instructions in response to user stimuluson scroll wheel 110, button 112, etc.

In addition, housing 102 can also define the shape or form of the mediaplayer. That is, the contour of housing 102 can embody the outwardphysical appearance of media player 100. The integrated circuit chipsand other circuitry contained within the housing can include amicroprocessor (e.g., CPU), memory (e.g., ROM, RAM), a power supply(e.g., battery), a circuit board, a hard drive, other memory (e.g.,flash) and/or various input/output (I/O) support circuitry. Theelectrical components can also include components for inputting oroutputting music or sound such as a microphone, amplifier and a digitalsignal processor (DSP). The electrical components can also includecomponents for capturing images such as image sensors (e.g., chargecoupled device (CCD) or complimentary oxide semiconductor (CMOS)) oroptics (e.g., lenses, splitters, filters). The electrical components canalso include components for sending and receiving media (e.g., antenna,receiver, transmitter, transceiver, etc.).

In the embodiment shown in FIG. 1, the media player 100 includes displayscreen 104 and related circuitry. Display screen 104 is used to displaya graphical user interface as well as other information to the user(e.g., text, objects, graphics). As shown, display screen 104 is visibleto a user of media player 100 through opening 105 in housing 102, andthrough transparent wall 106 disposed in front of opening 105.

As mentioned above, media player 100 also can include scroll wheel 110.Scroll wheel 110 generally consists of touchable outer surface 111 forreceiving a finger or other suitable object for manipulation on scrollwheel 110.

The position of display screen 104 and scroll wheel 110 relative tohousing 102 can be widely varied. For example, they can be placed at anyexternal surface (e.g., top, side, front, or back) of housing 102 thatis accessible to a user during manipulation of media player 100. In theillustrated embodiment, scroll wheel 110 is located in a lower, frontarea of housing 102.

In addition to the above, media player 100 can also include one or morebuttons 112. Button 112 can be configured to provide one or morededicated control functions for making selections or issuing commandsassociated with operating media player 100. In most cases, the buttonfunctions are implemented via a mechanical clicking action.

Moreover, the media player 100 can also include hold switch 114, aheadphone jack 116 and a data port (not shown).

The methods according to the invention can preferably implemented by acombination of hardware and software, but can also be implemented inhardware or software. The method can also be embodied as computerreadable code on a computer readable medium. The computer readablemedium is any data storage device that can store data which canthereafter be read by a computer system. Examples of the computerreadable medium include read-only memory, random-access memory, harddrive, flash memory, CD-ROMs, DVDs, magnetic tape, optical data storagedevices, and carrier waves.

FIG. 2 shows a top plan view of illustrative scroll wheel 202 and centerbutton 204. FIG. 2 also shows a portion of housing 206. FIG. 2 providesa reference figure for FIGS. 3 and 4 which follow and which show theinternal components of the media player shown in FIG. 2.

FIG. 3 shows a cross-section of scroll wheel 202, button 204, andhousing 206 from line A-A in FIG. 2. FIG. 3 shows scroll wheel 302,center button 304, dome switch 306, back plate 308, flexible printedcircuit board 310, stiffener plate 312, dome actuator 314, and assemblytolerance gap 316.

FIG. 3 also shows a number of exemplary approximate thicknessesaccording to one embodiment of the invention. The thickness legends havebeen included in the FIGURE for the sake of clarity. Each of the valuesshown in FIGS. 3 and 4 are in millimeters (mm). The thicknesses caninclude (starting from the left and moving towards the right) 0.70 mmfor the cosmetic housing thickness, about 0.40 mm for the stiffenerplate thickness, about 0.25 mm for the dome actuator height, about 0.12mm for the assembly tolerance gap which results from the design of howmuch distance exists from the actuator nubs to the actuator domes in aleast tolerant case scenario wherein the nub is as high as productspecifications allow and the dome is as low as product specificationsallow (if the domes are pre-loaded by the nubs, the switch may be in anON state even before it is depressed), about 0.28 mm for the dome switchheight, about 0.15 mm for the flexible printed circuit (FPC) height, andabout 0.65 mm for the scroll wheel thickness. One purpose ofpre-compressing the shims is that the pre-compression ensures that thetolerance gap remains consistently at a minimum substantiallyindependent of the operational conditions of the device. In oneembodiment of the invention the tolerance gap is transparent to theuser.

FIG. 4 shows a side view of a cross-section of scroll wheel 202, button204, and housing 206 from Line B-B in FIG. 2. FIG. 4 shows in pertinentpart flushness shim 401, scroll wheel 402, and FPC 410. The thicknessesshown in FIG. 4 include the thickness of the flushness foam of nominallyabout 0.65 mm, about 0.15 FPC thickness and about 0.65 wheel thickness.

FIG. 5 shows an exploded portion of FIG. 4 taken from curve C in FIG. 4.FIG. 5 shows retention ledge of housing surface 502, wheel surface 504and point of contact 506 between ledge 502 and wheel surface 504. Oneaspect of the invention can be to maintain the surface of the housingand the surface of the wheel as planar as possible all around thecircumference of the wheel across all the operational conditions of themedia player.

When the flushness shim is compressed, retention ledge 502 can touch allaround the circumference of the scroll wheel. It follows that, in thesituation of the flushness shim being compressed, the actual flushnessof ledge 502 and the scroll wheel can then be controlled by themanufacturing tolerances of the wheel and the housing. This situationcan be an optimal set of conditions for achieving one aforementionedgoal of the invention—i.e., to maintain the two surfaces as planar aspossible all around the circumference of the wheel across all theoperational conditions of the media player.

FIG. 6 shows an exploded perspective view from below of the flushnessshims and related apparatus according to one embodiment of theinvention. FIG. 6 shows housing 602, scroll wheel 604, adhesive 606,retainer 608, adhesive 610, FPC 612, dome switches 614, flushness shimfoam pieces 616 and stiffener plate 618.

FIG. 7 shows an exploded perspective view from above of the flushnessshims and related apparatus according to one embodiment of theinvention. FIG. 7 shows housing 702, scroll wheel 704, adhesive 706,retainer 708, adhesive 710, FPC 712 (dome switches not visible from thisperspective), flushness shim foam pieces 716 and stiffener plate 718.Stiffener plate 718 also shows dome switch actuator nubs 720.

A method according to the invention is shown in FIG. 8. Step 810 showsdetermining two or more surfaces in a portable media player for which adesired relationship may exist—e.g., a substantially coplanarrelationship. Step 820 shows placing compressible foam shims, a softspring or other suitable apparatus having a compressibility such thatthe desired relationship between the surfaces is obtained (withoutcompromising the other functions of apparatus associated with thesurfaces).

Step 830 shows pre-compressing the shims (or spring) in order tomaintain the relationship between the two surfaces across apre-determined operational range of the player. Step 840 shows sealingthe device such that the pre-compression of the shims (or spring) can befixed. It should be noted that at least steps 810, 820, and 840 includeoptional components relating to the apparatus for implementation of theinvention—i.e., shims, a spring, or other suitable apparatus.

FIG. 9 shows one embodiment of the invention having spring 916implemented as the apparatus for controlling the distance betweenhousing 902 and scroll wheel 904.

FIG. 10 shows that a plurality of small springs 1016 may be implementedinstead of the single large spring shown in FIG. 9.

The methods according to the invention can preferably implemented by acombination of hardware and software, but can also be implemented inhardware or software. The method can also be embodied as computerreadable code on a computer readable medium. The computer readablemedium is any data storage device that can store data which canthereafter be read by a computer system. Examples of the computerreadable medium include read-only memory, random-access memory, harddrive, flash memory, CD-ROMs, DVDs, magnetic tape, optical data storagedevices, and carrier waves.

It is therefore intended that the following appended claims beinterpreted as including all such alterations, permutations, andequivalents as fall within the true spirit and scope of the presentinvention. The embodiments described herein-above are further intendedto explain the best modes known of practicing the invention and toenable others skilled in the art to utilize the invention in such, orother embodiments and with the various modifications required by theparticular applications or uses of the invention.

Accordingly, the description is not intended to limit the invention tothe form disclosed herein. Also, it is intended that the appended claimsbe construed to include alternative embodiments.

1-9. (canceled)
 10. A method for obtaining a substantially coplanarrelationship between two surfaces in a portable media player, the methodcomprising: pre-compressing a plurality of foam shims; and placing theplurality of foam shims in the media player wherein the plurality offoam shims exerts a force on at least one of the two surfaces, the forceacting to obtain a substantially coplanar relationship between the twosurfaces.
 11. The method of claim 10 further comprising: maintaining atleast a portion of the force of the plurality of foam shims on the atleast one of the two surfaces across a pre-determined operational rangeof the media player.
 12. The method of claim 10 further comprising:determining which two surfaces in the media player would be enhanced bya substantially coplanar relationship.
 13. The method of claim 10further comprising: sealing the media player; and in response to thesealing, maintaining at least a portion of the force of the plurality offoam shims on the at least one of the two surfaces across apre-determined operational range of the media player.
 14. A method forobtaining a substantially coplanar relationship between two surfaces ina portable media player, the method comprising: pre-compressing at leastone spring; and placing the at least one spring in the media playerwherein the at least one spring exerts a force on at least one of thetwo surfaces, the force acting to obtain a substantially coplanarrelationship between the two surfaces.
 15. The method of claim 14further comprising: maintaining at least a portion of the force of theat least one spring on the at least one of the two surfaces across apre-determined operational range of the media player.
 16. The method ofclaim 14 further comprising: determining which two surfaces in the mediaplayer would be enhanced by a substantially coplanar relationship. 17.The method of claim 14 further comprising: sealing the media player; andin response to the sealing, maintaining at least a portion of the forceof the at least one spring on the at least one of the two surfacesacross a pre-determined operational range of the media player. 18-24.(canceled)
 25. A method for obtaining a pre-determined relationshipbetween two surfaces in a media player, the method comprising:pre-compressing a plurality of compressible shims, wherein, in responseto the pre-compression, the compressible shims provide a force thatcontributes to maintaining the pre-determined relationship across anoperational range of the media player.
 26. The method of claim 25,further comprising: placing the compressible shims in the media player.27. The method of claim 25, further comprising: sealing the media playerduring the pre-compressing so that at least a portion of the force ismaintained across the operational range of the media player.
 28. Themethod of claim 25, wherein the force provided by the compressible shimsis substantially constant across the operational range of the mediaplayer.
 29. The method of claim 25, wherein the force provided by thecompressible shims maintains a tolerance gap at a minimum substantiallyindependent of operational conditions across the operational range ofthe media player.
 30. The method of claim 25, wherein the pre-determinedrelationship between the two surfaces is controlled by manufacturingtolerances when the compressible shims are compressed beyond thepre-compression.
 31. The method of claim 25, wherein: a first surface ofthe two surfaces is an outer surface of a scroll wheel; and a secondsurface of the two surfaces is a housing of the media player.
 32. Themethod of claim 10, wherein the force exerted by the foam shims issubstantially constant across a pre-determined operational range of themedia player.
 33. The method of claim 10, wherein the force exerted bythe foam shims maintains a tolerance gap at a minimum substantiallyindependent of operational conditions across a pre-determinedoperational range of the media player.
 34. The method of claim 10,wherein the relationship between the two surfaces is controlled bymanufacturing tolerances when the foam shims are compressed beyond thepre-compression.
 35. The method of claim 10, wherein: the at least oneof the two surfaces is an outer surface of a scroll wheel; and anotherone of the two surfaces is a housing of the media player.
 36. The methodof claim 14, wherein the force exerted by the at least one spring issubstantially constant across a pre-determined operational range of themedia player.
 37. The method of claim 14, wherein the force exerted bythe at least one spring maintains a tolerance gap at a minimumsubstantially independent of operational conditions across apre-determined operational range of the media player.
 38. The method ofclaim 14, wherein the relationship between the two surfaces iscontrolled by manufacturing tolerances when the at least one spring iscompressed beyond the pre-compression.
 39. The method of claim 14,wherein: the at least one of the two surfaces is an outer surface of ascroll wheel; and another one of the two surfaces is a housing of themedia player.